Flexible container with integrated support structure

ABSTRACT

A flexible container is disclosed having a base member and walls extending from the base member. The flexible container is reinforced by a support structure integrally attached thereto, the support having a base support for reinforcing the base of the container and a side support for reinforcing the side walls of the container.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional App. No.60/506,174 filed on Sep. 26, 2003, the entire contents of which isincorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention generally relates to flexible containers, and inparticular, molds constructed of a flexible silicone elastomer materialhaving an integrated support structure.

Molds made of flexible or deformable materials are known and widely usedfor cooking on professional and domestic levels. One example of suchmolds is bakeware containing silicone elastomer material, hereinreferred to as “silicone bakeware.” There are many advantages to usingsilicone bakeware. The principal advantage is the flexibility of thesilicone bakeware. Flexible bakeware allows the user to more easilyremove baked items from the bakeware. Furthermore, the chemicalcomposition of silicone bakeware typically provides a slick interiorsurface, eliminating the need to grease and flour the pans and allowingthe baked items to easily slip out of the bakeware. Another advantage offlexible bakeware is that when it is not in use, it can be stored in afolded state, thereby minimizing the storage room necessary.

The main characteristic of silicone bakeware is that it remainsthermally stable and non-toxic over a broad temperature range. As aresult, the silicone bakeware can go from the refrigerator or freezer tothe oven, and thereafter into a dishwasher. For example, the same moldcan be used for preparing ice cream cakes at very low temperatures(e.g., −140° F.) and for baking cakes at high temperatures (e.g., 500°F.). Moreover, the molds can be used in the microwave. After use, themolds can be easily cleaned by hand or in the dishwasher.

A disadvantage of the known flexible molds is that when filled withfood, particularly food that is heavy in nature, the mold does notalways maintain its shape. Because of its flexible nature, the walls ofthe mold can bulge, slant or otherwise fail to maintain their linear,vertical orientation. As a result, food baked therein may not have theintended shape because the mold was unable to retain its shape in thebaking process. Furthermore, the flexible nature of the mold makes themold unstable during movement. So, for example, when the mold is grippedand lifted, the mold may deform causing overflow of the liquid,semi-liquid or pasty contents or the breakage of the solid or semi-solidcontents.

It would therefore be desirable to provide a flexible mold that hassufficient structural support to prevent the buckling or slanting of themold walls and to prevent deformation of the mold during movement.

SUMMARY OF THE INVENTION

A flexible container is disclosed having a base member and wallsextending from the base member. The flexible container is reinforced bya support structure integrally attached thereto, the support having abase support for reinforcing the base of the container and a sidesupport for reinforcing the side walls of the container.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a preferred embodiment of the flexiblecontainer of the present invention having an integrated supportstructure;

FIG. 2 depicts a portion of a preferred embodiment of the supportstructure of the present invention;

FIG. 3 depicts another preferred embodiment of the support structure ofthe present invention; and

FIG. 4 depicts another preferred embodiment of the invention having anextended portion on the lip thereof.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIG. 1, a preferred embodiment of the flexible container 10of the present invention includes a base member 12 and side walls 14extending from the base member 12. In the embodiment shown in FIG. 1,container 10 has a rectangular shape. It is envisioned that thecontainer of the present invention can be of any shape or size,including various geometrical shapes (e.g., circular, square,triangular, rectangular, oval, polygonal) or can be in the shape of anarticle, character or other artwork. Accordingly, the appearance andshape of the container should not be limited to that shown in thedrawings or described herein.

Furthermore, although the terms bakeware and mold are used herein, theinvention is intended to include any flexible cooking container,regardless of the type of food prepared therein or the method ofpreparation. Bakeware and mold are simply terms used to describepreferred embodiments of the invention. As such, these terms should notbe construed as limiting the scope of the invention.

In a preferred embodiment of the invention, as shown in FIG. 1, theflexible container 10 includes a lip or edge 16 extending from the sidewalls 14. The thickness of the lip 16 is preferably greater than thethickness of the side walls 16. The lip 16 preferably includes atextured surface to provide assistance in maintaining a grip on the lip16 and to reduce the risk of the lip slipping from one's grasp.

The flexible container 10 is reinforced by support structure 20. In apreferred embodiment of the invention, the support structure 20 includesa base support 22 and a side support 24. In the embodiment shown in FIG.1, the base support includes two cross-members 26 that form an “X”across the base member 12 of the container. The cross-members 26 haveextended arms 28 that connect to the side support 24.

In a preferred embodiment of the invention, side support 24 includes aseries of support sections 30. The benefit of using support sections 30is that during the manufacturing process, the versatility of the supportsections 30 enables one to use the same pieces to create supportstructures 20 for containers of various sizes and shapes. Furthermore,by using support sections 30, the side support 24 can tolerate a certaindegree of expansion resulting from heat or other environmentalconditions.

The support sections 30 are preferably interconnected by couplingmembers 32. In the embodiment shown in FIGS. 1 and 3, coupling members32 are spherical beads having an opening therethrough. Each end of asupport section 30 is inserted in the opening of a coupling member 32.The size of the opening should be selected such that the coupling member32 firmly grips the end of the support section 30, thereby securelycoupling one support section to an adjoining support section. Thecoupling member is not limited to the embodiment described herein butencompasses any device that can interconnect adjoining support sections.

In a preferred embodiment of the invention the support sections are madeof stainless steel, having a diameter of 1.5 to 2 mm. The sphericalbeads preferably are made of a material containing silicone. Thoseskilled in the art will know that other materials can be substituted forthose described herein.

In FIG. 1, the side support 24 is shown positioned adjacent the bottomsurface 18 of edge 16. However, the position of the side support 24 canbe adjusted to provide structural support where needed. For example, theside support 24 can be positioned at or near the center of the sidewall. The side walls 14 and/or edge 16 preferably have channels 34 toreceive coupling members 32. The coupling member 32 should be sized tobe slightly smaller than the size of channel 34.

The support structure 20 is preferably not removable from the flexiblecontainer 10. In another preferred embodiment, the support structure isintegrally molded with the flexible container 10. During themanufacturing process, after the support structure is constructed, thestructure can be inserted into the mold and integrally molded with theflexible container 10. Alternately, during the molding process, theflexible container 10 can be manufactured with receiving channelstherein, and the support structure 20 can be snap-fitted into thereceiving channels. The manufacturing techniques described herein arefor exemplary purposes only. Other known manufacturing techniques can beemployed by those skilled in the art.

FIG. 2 depicts another preferred embodiment of the invention, whereinthe side support 24 is an integral assembly attached to the base support22, forming a unitary support structure 20. It is within the scope ofthe invention for side support 24 and base support 22 to be manufacturedas a unitary structure or as one or more pieces that are connected toeach other.

FIG. 4 depicts another preferred embodiment of the invention, whereinlip 16 has an extended portion 40. Extension portion 40 can be adaptedto receive a logo. In another embodiment of the invention, the lip 16carries at least two extended portions 40, one on each side of thecontainer (not shown). The extended portions are sized and positioned tofacilitate the grip of a user, thereby assisting the user in grasping,lifting or moving the flexible container. In yet another preferredembodiment of the invention, the extended portion 40 includes anaperture therein (not shown) that facilitates the hanging of theflexible container from a hook, thereby providing an alternate method ofstoring the container.

Many modifications and other embodiments of the invention set forthherein will come to mind to one skilled in the art to which theinvention pertains having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the invention is not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

1. A flexible container, comprising: a base member; at least one wallextending from the base member, the at least one wall defining aperiphery; a support structure having a base support and a side support,wherein the base support is adapted to reinforce the base member and theside support is adapted to reinforce the at least one wall; and whereinthe base support is integrally attached to the base member.
 2. Theflexible container of claim 1 wherein the base support is molded withbase member.
 3. The flexible container of claim 1 wherein the sidesupport extends completely about the periphery of the at least one sidewall.
 4. The flexible container of claim 1 wherein the side supportcomprises a plurality of support sections.
 5. The flexible container ofclaim 4 wherein the plurality of support section comprises first andsecond support section adjoining each other, wherein the first andsecond support section are joined by a coupling member.
 6. The flexiblecontainer of claim 5 wherein the coupling member is bead-shaped.
 7. Theflexible container of claim 5 wherein the coupling member comprisessilicone.
 8. The flexible container of claim 1 wherein the base membercomprises cross-members forming an X-shape.
 9. The flexible container ofclaim 1, wherein the support structure comprises stainless steel. 10.The flexible container of claim 1, wherein the support structurecomprises a wire assembly having a diameter of about 1.5 to 2 mm. 11.The flexible container of claim 1 wherein the support structure is anintegral, unitary assembly.
 12. The flexible container of claim 1further comprising a lip extending from the at least one side wall,wherein the lip includes an extended portion and wherein the extendedportion is adapted to receive a logo therein.
 13. The flexible containerof claim 1 wherein the at least one side wall comprises a first wall anda second wall opposite the first wall, a lip extends around theperiphery, and the lip carries a first extended portion proximal thefirst wall and a second extended portion proximal the second wall.
 14. Aflexible container, comprising: a base member; at least one wallextending from the base member, the at least one wall defining aperiphery; a support structure having a base support and a side support,wherein the base support is adapted to reinforce the base member and theside support is adapted to reinforce the at least one wall; and whereinthe base support is integrally attached to the base member and the sidesupport comprises at least two support sections joined together by ancoupling member.
 15. The flexible container of claim 14 wherein thecoupling member is bead-shaped.
 16. The flexible container of claim 14wherein the coupling member comprises silicone.
 17. A method of making aflexible container having an integral support structure, comprising thesteps of: providing a support structure assembly; placing the supportstructure assembly inside a mold; and molding the container on thesupport structure assembly.
 18. The method of claim 17 wherein thesupport structure comprises a wire assembly and the step of molding thecontainer comprises pouring a mixture comprising silicone onto the wireassembly in the mold.